US2021129116A1PendingUtilityA1

Method for producing coating layer for exhaust gas purification catalyst device

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Assignee: TOYOTA MOTOR CO LTDPriority: Nov 1, 2019Filed: Oct 1, 2020Published: May 6, 2021
Est. expiryNov 1, 2039(~13.2 yrs left)· nominal 20-yr term from priority
Inventors:Jota YamauchiToshihisa YamauchiYohei KinoshitaTakahiro Hayashi
B01J 35/40B01J 2235/00B01J 23/63B01D 53/86B01J 37/0036B01J 37/0201B01J 23/44B01J 37/0018B01J 23/002B01J 37/088B01J 37/0215B01J 37/0009B01D 2255/407B01D 2255/9202B01D 53/9413B01D 2255/1023B01D 2255/91B01D 2255/2092B01J 23/10B01J 37/0236B01J 37/0219B01D 53/94B01J 35/026
47
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Claims

Abstract

A method is provided for producing a coating layer for an exhaust gas purification catalyst device that can inhibit detachment of the coating layer when the coating layer is formed on the exhaust gas purification catalyst device. The method comprises covering a substrate with a slurry that comprises carrier particles and a dispersing medium, to form a slurry layer on the substrate, and drying and firing the slurry layer to form a coating layer, wherein the carrier particles have a median diameter (D50) of 4.00 μm or smaller, the dispersing medium comprises water and a water-soluble alcohol, and the amount of the water-soluble alcohol in the slurry is 0.50 mass % to 12.00 mass % with respect to the slurry.

Claims

exact text as granted — not AI-modified
1 . A method for producing a coating layer for an exhaust gas purification catalyst device, the method comprising:
 covering a substrate with a slurry containing carrier particles and a dispersing medium to form a slurry layer on the substrate, and   drying and firing the slurry layer to form a coating layer, wherein   the carrier particles have a median diameter (D50) of 4.00 μm or smaller,   the dispersing medium comprises water and a water-soluble alcohol, and   the amount of the water-soluble alcohol in the slurry is 0.50 mass % to 12.00 mass % with respect to the slurry.   
     
     
         2 . The method according to  claim 1 , wherein the median diameter (D50) of the carrier particles is 3.00 μm or smaller. 
     
     
         3 . The method according to  claim 1 , wherein the surface tension of the water-soluble alcohol is lower than the surface tension of water. 
     
     
         4 . The method according to  claim 1 , wherein the water-soluble alcohol is methanol, ethanol, 1-propanol, 2-propanol, ethylene glycol or glycerin, or a combination thereof. 
     
     
         5 . The method according to  claim 1 , wherein the amount of the water-soluble alcohol in the slurry is 0.50 mass % to 2.00 mass % with respect to the slurry. 
     
     
         6 . The method according to  claim 1 , wherein the viscosity of the slurry is 2000 mPa·s to 4000 mPa·s. 
     
     
         7 . The method according to  claim 1 , wherein the catalyst metal is supported on the carrier particles. 
     
     
         8 . The method according to  claim 7 , wherein the catalyst metal is Rh, Pt or Pd, or a combination thereof. 
     
     
         9 . The method according to  claim 1 , wherein the carrier particles are silica (SiO 2 ), zirconia (ZrO 2 ), ceria (CeO 2 ), alumina (Al 2 O 3 ) or titania (TiO 2 ), or a solid solution thereof, or a combination thereof. 
     
     
         10 . The method according to  claim 1 , wherein the substrate is made of a ceramic or metal.

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